Cutting tools and machining methods using cutting tools

ABSTRACT

Cutting tools and machining methods using cutting tools are disclosed. An example cutting tool comprises a shank and a head on the shank, the head comprising a diamond abrasive-coated cutting surface, the cutting head having grooves interrupting the cutting surface and extending from the cutting surface toward an axis of rotation of the head, the cutting surface having a substantially constant radius.

CROSS REFERENCE TO RELATED APPLICATIONS

This patent arises from a continuation of U.S. patent application Ser.No. 12/987,364, filed Jan. 10, 2011, which claims priority toProvisional U.S. Patent Application No. 61/412,522 filed Nov. 11, 2010.The entireties of U.S. patent application Ser. No. 12/987,364 andProvisional U.S. Patent Application No. 61/412,522 are incorporatedherein by reference.

TECHNICAL FIELD

The disclosure generally relates to producing the shimming process wherefillers are applied to assembly process of filling gaps in mechanicalstructures. There are two object classifications for filling gaps instructure, shims which are made from peelable laminated materials andfillers which are precisely machined form solid monolithic materials.More particularly, the disclosure relates to an automated process ofdefining, producing and tracking the status of custom fillers producedon demand for immediate installation on an inline flow production linewhen the full design definition of a structure resides in a CAD/CAMsystem.

BACKGROUND

In the fabrication of mechanical structures such as aircraft, it may benecessary to introduce fillers between interfacing surfaces of thecomponent parts to assure proper and safe structure. Fillers (also knownas shims) are pieces of metallic or non-metallic materials which areplaced in gaps between the component parts to compensate for dimensionalvariations or tolerance buildup between the parts. In the aircraftindustry, fillers may be used in fitting and joining major structuralsections to one another and throughout substructures as they arebuilt-up into a full aircraft structure. The use of fillers maycompensate for dimensional variation between parts or bring parts intoproper alignment.

A conventional method of defining and producing custom fillers mayinclude measuring gaps between parts using feeler gauges, capacitive gapmeasuring instrumentation or computer/laser based scanning measurementsystems. The gap measurement data may be documented and delivered viaentry into a series of software capabilities which process the gapmeasurements, updated digital definitions of the fillers and generatesportable Machine Control Data (MCD). The MCD is downloaded to a centralserver which delivers the MCD to a Computer Numerical Control (CNC)controlled machine tool. The CNC machine tool machines the filler usingcutting tool configurations which are specific to the filler and itsmaterial being manufactured. Following the machining of the filler onits surface and profile, it is de-burred and the filler marked with itsidentification to facilitate its installation in the structure.

In previous applications, the conventional filler definition andelements of the production process may be paper-based. In someproduction schemes, however, the full design definition of the structurewhich is being fabricated may be digitally defined and electronicallystored and processed in a CAD/CAM system such as CATIA V5 and Enovia.For large-scale production of aircraft, the design definition of anaircraft may be defined by engineers from many companies which designvarious sections of the aircraft. That digital definition establishesand maintains the full definition of all components in their spatialrelationship—in aircraft coordinates. The fabricated aircraft sectionsundergo final assembly at an aircraft assembly plant.

In current aircraft production schemes, an automated process ofdefining, producing and tracking the status of custom fillers on demandfor immediate installation on an inline flow production line when thefull design definition of a structure resides in a CAD/CAM system isrequired.

SUMMARY

The disclosure is generally directed to an automated filler productionmethod. The automated filler production method is suitable for defining,producing and tracking the status of custom fillers on demand forimmediate installation on an inline flow production line when the fulldesign definition of a structure resides in a CAD/CAM system. Anillustrative embodiment of the method includes obtaining gap measurementdata by measuring a gap between component parts of a structure,delivering the gap measurement data to a data collector function,updating the CAD solid model of the filler (in its relationship in thestructure) using the gap measurement data, creating portable MachineControl Data (MCD) using the CAM function of the CADCAM system,delivering the MCD to a filler machining center via a networked server,and machining a filler from a metallic or non-metallic compositematerials using the MCD.

In some embodiments, the automated filler production method may includeobtaining gap measurement data by measuring a gap between componentparts of a structure; capturing and delivering the gap measurement datato a data collector function; generating a new CAD solid modeldefinition with the gap measurements, creating portable Machine ControlData (MCD) using the CAM function of the CADCAM system, delivering theMCD to a filler machining center via a networked server, and machining afiller from a metallic or non-metallic composite materials using theMCD.

The disclosure is further generally directed to a method of applying adiamond abrasive cutting tool configuration to the fabrication offillers from large sheets of non-metallic composite material. Anillustrative embodiment of the method includes providing a cutting toolincluding a tool shank, a tool head attached to the tool shank andindividual diamond abrasive cutting edges attached to the tool head;providing a non-metallic composite filler materials; and machining afiller from the filler from larger sheets of material using the cuttingtool.

The features, functions, and advantages that have been discussed can beachieved independently in various embodiments of the present disclosureor may be combined in yet other embodiments further details of which canbe seen with reference to the following description and drawings.

BRIEF DESCRIPTION OF THE ILLUSTRATIONS

FIG. 1 is a flow diagram of an illustrative embodiment of the automatedfiller production method.

FIG. 1A is a flow diagram of an illustrative embodiment of a method ofapplying a diamond abrasive cutting tool configuration which enablesunique gauge reduction material removal capabilities for non-metalliccomposite materials.

FIGS. 2 and 2A are side and end views, respectively, of a diamondabrasive cutting tool configuration which enables the unique gaugereduction material removal capabilities of non-metallic compositematerials in implementation of the automated filler production method.

FIGS. 3 and 3A are side and end views, respectively, of an alternativediamond abrasive cutting tool configuration.

FIGS. 4 and 4A are side and end views, respectively, of anotheralternative diamond abrasive cutting tool configuration.

FIGS. 5 and 5A are side and end views, respectively, of still anotheralternative diamond abrasive cutting tool configuration.

FIG. 6 is a flow diagram of an aircraft production and servicemethodology.

FIG. 7 is a block diagram of an aircraft.

DETAILED DESCRIPTION

The following detailed description is merely exemplary in nature and isnot intended to limit the described embodiments or the application anduses of the described embodiments. As used herein, the word “exemplary”or “illustrative” means “serving as an example, instance, orillustration.” Any implementation described herein as “exemplary” or“illustrative” is not necessarily to be construed as preferred oradvantageous over other implementations. All of the implementationsdescribed below are exemplary implementations provided to enable personsskilled in the art to practice the disclosure and are not intended tolimit the scope of the claims. Furthermore, there is no intention to bebound by any expressed or implied theory presented in the precedingtechnical field, background, brief summary or the following detaileddescription.

The disclosure is generally directed to an integrated automated fillerproduction method from gap measurement, filler definition, NC (NumericalControl) programming, filler machining (regardless of the materialtype), delivery of fillers for the assembly of a structure such as acomposite aircraft, and filler status tracking The method may beembodied in software which enables integration of these processes andassures the quality of the finished filler. The disclosure is furthergenerally directed to the configuration, features and method ofapplication of a diamond abrasive cutting tool configuration whichenables the unique gauge reduction material removal capabilities ofnon-metallic composite materials (GFRP and CFRP). Additionally, themethods may enable the production of multiple metallic material fillersutilizing their unique required cutter configurations.

Referring initially to FIG. 1, a flow diagram 100 of an illustrativeembodiment of the automated filler production method is shown. Themethod 100 may be implemented in the integration of fillers during theproduction of aircraft or other structures. In block 102, measurement ofa gap between component parts of the aircraft or other structure may bemade. The gap measurement may be made by multiple methods—mechanical,electrical, or computer based, for example and without limitation. Theaccuracy of the gap measurement capture is assured through a graphicaluser interface for the data collection function.

In block 104, the gap measurement data obtained in block 102 may becaptured and delivered to a data collector function which is adapted todisplay and assess all measurement points and then to deliver theproperly formatted measurement data to a proper server location. A“watcher” function transmit notifications to personnel who areresponsible for supporting the filler machining process that newmeasurement data has arrived and if the gap measurements meet specifieddesign criteria. Automated entry of the gap measurement data to the datacollector function may be made via interfaces with the measurementequipment. The gap measurement data may be transmitted to the datacollector function via a factory wireless network or via directhardwired network connection. Upon receipt of the gap measurement file,an automatic population of a filler CAD definition with the measurementdata may occur.

In block 106, a solid model of the structure, including the filler solidmodel, may be updated with the population of filler CAD definitioncarried out in block 104. An automated update of the NC (Numericcontrol) program for the machining process may be generated from theupdated solid model and the creation of portable Machine Control Data(MCD) may be accomplished. An automated download of the MCD to a centralserver may be accomplished. In block 108, a status update to noteavailability of the MCD may be accomplished.

In block 110, a direct delivery of the MCD to a machining center may begenerated such as by request from a machinist and the filler may bemachined from a larger sheet of material. In some embodiments, the sheetof material from which the filler is machined may be a compositematerial in the form of Glass Fiber Re-enforced Plastic (GFRP) or CarbonFiber Re-enforced Plastic (CFRP) or other non-metallic materials. Inother embodiments, the material sheet from which the filler is machinedmay be metallic in nature. If necessary, machining of the filler may beshifted within the material sheet envelope to assure maximum materialutilization. Highly-specialized cutting tool configurations may beutilized by the MCD to machine the complex filler surfaces. The fillermay be machined from a material which may be of any type includingcomposite non-metallic, and metallic materials, for example and withoutlimitation.

In block 112, changes in the status of the filler through out itsfabrication process may be logged and reported as required. In block114, deburring of the filler may be carried out and the filler may bemarked for incorporation into the structure. The filler may beimmediately installed on an inline flow production line or retained forfuture use depending on the production strategy.

It will be appreciated by those skilled in the art that the method ofthe disclosure may be implemented to define, produce, and ascertain anddistribute the status of fillers that are custom-produced on demand forimmediate installation on an inline flow production line in applicationsin which the full design requirement of an aircraft or other structureresides solely in a CAD/CAM system. It will be further appreciated bythose skilled in the art that the method 100 may support 5-axis machinetools, 3D engineering definition of an aircraft or other structure,automatic capture of gap measurement data, automated delivery of the gapmeasurement data, machining of composite materials, automated generationof the Machine Control Data (MCD), delivery of the MCD to the machinetool and automated filler status collection, communication, and storagefor future performance and process analysis.

Referring next to FIG. 1A, a flow diagram 100 a of an illustrativeembodiment of a method of applying a diamond abrasive cutting toolconfiguration which enables unique gauge reduction and complex surfacegeneration via material removal techniques of non-metallic compositematerials is shown. In some applications, the flow diagram 100 a may beimplemented as part of block 110 of the flow diagram 100 which washeretofore described with respect to FIG. 1. In block 102 a, a cuttingtool having a tool shank, an attached material removal cutting head onthe tool shank and diamond abrasive cutting material applied on allmaterial removal surfaces including grooves formed to facilitate thematerial removal process is provided. The cutting tool may have one ofthe cutting tool configurations which are described with respect toFIGS. 2-5A herein below. In block 104 a, a non-metallic filler materialsheet is provided. In some embodiments, the non-metallic filler materialsheet may be a composite material, such as CFRP and GFRP. In block 106a, a filler may be fabricated from the filler material sheet using thecutting tool provided in block 102 a. It should be noted that a filleror multiple instances of the filler may be located in a single sheet ofmaterial. Additionally, multiple filler configurations may grouped in asingle sheet of filler material and sequentially without interruption ofthe process to load material or to unload material and/or fillers.

Referring next to FIGS. 2-5A of the drawings, various cutting toolconfigurations for production of fillers according to the method of thedisclosure are shown. For example and without limitation, the cuttingtool configurations shown in FIGS. 2-5A may be implemented in block 110of the flow diagram 100 which was heretofore described with respect toFIG. 1 and in the flow diagram 100 a which was heretofore described withrespect to FIG. 1A. Application of the cutting tool configurations mayenable the unique gauge reduction and complex surface generation viamaterial removal capabilities of the non-metallic composite materials(such as GFRP and CFRP).

As illustrated in FIGS. 2 and 2A, in some embodiments the cutting tool 1may include a generally elongated tool shank 2 having an attachedmaterial removal cutting head 3 on the tool shank 2. The attachedmaterial removal cutting head 3 may have a generally semisphericalproximal head portion 3 a and a generally semispherical cutting surface3 b which extends from the proximal head portion 3 a. Diamond abrasiveis applied on the material removal surfaces including grooves formed tofacilitate the material removal process 4 may extend along the cuttingsurface 3 b of the attached material removal cutting head 3. As shown inFIG. 2A, in some embodiments, the grooves formed to facilitate thematerial removal process 4 may be generally arranged in helical orstraight patterns on the cutting surface 3 b to facilitate the materialremoval process.

As shown in FIGS. 3 and 3A, in some embodiments the cutting tool 1 a mayinclude attached material removal cutting head 3 having a generallycylindrical proximal head portion 3 a and a generally semisphericalcutting surface 3 b which extends from the proximal head portion 3 a.The grooves formed to facilitate the material removal process 4 mayextend along the cutting surface 3 b of the attached material removalcutting head 3.

As shown in FIGS. 4 and 4A, in some embodiments, the attached materialremoval cutting head 3 of the cutting tool lb may include a generallycylindrical proximal head portion 3 a and a generally cylindrical sidecutting surface 3 b with a generally planar end cutting surface 3 c. Anannular cutting surface to facilitate the material removal process andto enable the generation of complex surfaces 3 d which may be curved incross-section and may circumscribe the end cutting surface 3 c. Diamondabrasive coated grooves formed to facilitate the material removalprocess 4 may extend along the side cutting surface 3 b, the radiusedcutting surface edge 3 d and the end cutting surface 3 c.

As shown in FIGS. 5 and 5A, in some embodiments the attached materialremoval cutting head 3 of the cutting tool 1 c may include a generallycylindrical proximal head portion 3 a and a generally cylindrical sidecutting surface 3 b with an annular cutting surface edge 3 d. As shownin FIG. 5A, the material removal cutting head 3 may have a cuttingsurface bore 3 e to facilitate material removal. Diamond abrasivecutting ridges 4 may extend along the side cutting surface 3 b and ontothe cutting surface edge 3 d of the material removal cutting head 3 andinto the area defined by 3 e.

Referring next to FIGS. 6 and 7, embodiments of the disclosure may beused in the context of an aircraft manufacturing and service method 78as shown in FIG. 6 and an aircraft 94 as shown in FIG. 7. Duringpre-production, exemplary method 78 may include specification and design80 of the aircraft 94 and material procurement 82. During production,component and subassembly manufacturing 84 and system integration 86 ofthe aircraft 94 takes place. Thereafter, the aircraft 94 may go throughcertification and delivery 88 in order to be placed in service 90. Whilein service by a customer, the aircraft 94 may be scheduled for routinemaintenance and service 92 (which may also include modification,reconfiguration, refurbishment, and so on).

Each of the processes of method 78 may be performed or carried out by asystem integrator, a third party, and/or an operator (e.g., a customer).For the purposes of this description, a system integrator may includewithout limitation any number of aircraft manufacturers and major-systemsubcontractors; a third party may include without limitation any numberof vendors, subcontractors, and suppliers; and an operator may be anairline, leasing company, military entity, service organization, and soon.

As shown in FIG. 7, the aircraft 94 produced by exemplary method 78 mayinclude an airframe 98 with a plurality of systems 96 and an interior116. Examples of high-level systems 96 include one or more of apropulsion system 118, an electrical system 120, a hydraulic system 122,and an environmental system 124. Any number of other systems may beincluded. The assembly and/or installation requires filler to assureproper assembly and installation procedure as defined by the productdesign criteria. Although an aerospace example is shown, the principlesof the invention may be applied to other industries, such as theautomotive industry.

The apparatus embodied herein may be employed during any one or more ofthe stages of the production and service method 78. For example,components or subassemblies corresponding to production process 84 maybe fabricated or manufactured in a manner similar to components orsubassemblies produced while the aircraft 94 is in service. Also one ormore apparatus embodiments may be utilized during the production stages84 and 86, for example, by substantially expediting assembly of orreducing the cost of an aircraft 94. Similarly, one or more apparatusembodiments may be utilized while the aircraft 94 is in service, forexample and without limitation, to maintenance and service 92.

Although the embodiments of this disclosure have been described withrespect to certain exemplary embodiments, it is to be understood thatthe specific embodiments are for purposes of illustration and notlimitation, as other variations will occur to those of skill in the art.

What is claimed is:
 1. A cutting tool, comprising: a shank; and a headon the shank, the head comprising a diamond abrasive-coated cuttingsurface, the head having grooves interrupting the cutting surface andextending from the cutting surface toward an axis of rotation of thehead, the cutting surface having a substantially constant radius.
 2. Acutting tool as defined in claim 1, wherein the cutting surface iscylindrical, the head further comprises a planar end cutting surface,and an edge of the head between the cutting surface and the end cuttingsurface is radiused.
 3. A cutting tool as defined in claim 2, whereinthe grooves extend from the planar end cutting surface to an upper edgeof the cutting surface.
 4. A cutting tool as defined in claim 1, whereinthe shank is to be operatively coupled to a Computer Numerical Control(CNC) machine.
 5. A cutting tool as defined in claim 1, wherein the headis hemispherically shaped.
 6. A cutting tool as defined in claim 1,wherein the grooves are helically shaped.
 7. A cutting tool as definedin claim 1, wherein the cutting surface has the substantially constantradius in an axial direction of the head.
 8. A cutting tool as definedin claim 1, wherein the cutting tool is to perform cutting with thediamond abrasive-coated cutting surface.
 9. A method of applying adiamond abrasive cutting tool configuration to machining of a fillerfrom a non-metallic composite material, comprising: engaging a fillermaterial sheet with a cutting tool, the cutting tool including a shankand a head on the shank, the head comprising a diamond abrasive-coatedcutting surface, the head having grooves interrupting the cuttingsurface and extending from the cutting surface toward an axis ofrotation of the head, the cutting surface having a substantiallyconstant radius; and machining a filler from the filler material sheetusing the cutting tool.
 10. A method as defined in claim 9, whereinengaging the filler material sheet comprises engaging the fillermaterial sheet with a cylindrical cutting surface, the head furthercomprises a planar end cutting surface, and an edge of the head betweenthe cutting surface and the end cutting surface is radiused.
 11. Amethod as defined in claim 10, wherein the grooves extend from theplanar end cutting surface to an upper edge of the cutting surface. 12.A method as defined in claim 9, wherein the shank is to be operativelycoupled to a Computer Numerical Control (CNC) machine.
 13. A method asdefined in claim 9, wherein the head is hemispherically shaped.
 14. Amethod as defined in claim 9, wherein the grooves are helically shaped.15. A method as defined in claim 9, wherein the cutting surface has thesubstantially constant radius in an axial direction of the head.
 16. Amethod as defined in claim 9, wherein the cutting tool is to performcutting with the diamond abrasive-coated cutting surface.